Automated Low Cost 3D Scanning

Automated Low Cost 3D Scanning

Nasir Mannan, CCAT
Thomas Tong, 3D3 Solutions

© 2010 Connecticut Center for Advanced Technology Inc. All rights reserved.

About CCAT

• CCAT-The Connecticut Center for Advanced Technology, Inc.
• NCAL-National Center for Aerospace Leadership.
• Nonprofit organization that serves as economic development center for
excellence for the region, state and nation.
• Core programs address military and civilian industrial manufacturing
needs.
• Collaborating with 3D3 Solutions to develop push button 3D scanning
solutions in the aerospace and automotive industries.


About 3D3 Solutions

• 3D3 Solutions is a research and development company that develops 3D
scanning technology.
i t h l
• Our focus is on flexible white light 3D scanning systems.
• Works with companies to develop custom scanning solutions for specific
needs such as high resolution, high speed or low cost.
g , g p


Overview/Introduction

Current Manufacturing Process
• F small and medium sized businesses
For ll d di i db i
• Common metrology process
• Equipment
Issue
• Bottlenecking
Resolution
• I t d ti t non-contact measurement
Introduction to t t t
• Making it easy to use
• Making it cost effective
• H ldi the accuracy
Holding h
• Reporting


Small and Medium Businesses

• Suppliers to major OEM companies
• Limited on resources and specialized skilled workers
• Most produce parts for OEM’s at high rates
• Must produce parts to quality standard
• Have limited budgets for improvements
• Have limited resources to research new technologies


Equipment for Quality Control

As parts come off from manufacturing it goes to quality control.
There are two basic pathways for inspection.

Coordinate Measuring Machines Hand Gauging Tools


Common Metrology Process


Bottlenecking

Bottlenecking occurs when
parts are manufactured
faster than they are being
inspected during the quality
control process.
3 hours

2 weeks


Bottlenecking


Resolution: Non-Contact Measurement

Use of 3D scanning to measure parts for quality inspection.


White Light 3D Scanning Systems

• A projector projects a series of
reference patterns onto the scan
object.
• The scene is captured using 1 or 2
cameras.
cameras
• 3D scanning software processes
the images from the cameras to
acquire the data needed to create a
q
3D model.
• Compared to a laser scanner, it
takes a full view of the object
instead of using laser beam.
i d f i l b
• Takes a few seconds to create a
single scan.


Automation

• One button
O b tt scanning i
• 3D scanning generally takes lots of work
(depends on the complexity of the scan object)
• Goal of technology is to save time effort
• Whole object scanning with a single click


Automating the Pipeline

4. Data
Scan 1. Acquire 2. Scan 3. Scan
Filtering and Report or
Data Alignment Merging
Conversion Manufacturing


Complete Data Acquisition

• If the object is small and easily moved: Move the object
• If the object is large and difficult to move: Move the scanner


Multiple Scanners

• The
Th use of multiple scan heads controlled by one PC
f lti l h d t ll d b
• Fast 3D data capture


Data Alignment

One scanner
• Manual feature alignment
• Motion control alignment
• Photogrammetric dots

Multiple scanners
• Geometric object alignment


Data Cleanup

Automated Cleanup
• Noise Filters
• H l Filli
Hole Filling
• Scan Merging
• Abnormal Triangles
• S
Smoothing
thi

one scan (left) vs. multiple scans of an object (right)


Making it Cost Effective: Data Acquisition

Individual
I di id l scans need to be highly
d b hi hl
accurate because downstreaming
cannot improve the quality and
accuracy of the d
f h data.


Making it Cost Effective: Hardware

• Small d
S ll and mediums businesses have a limited resources
di b i h li i d
• Make technology cost effective by using off-the shelf hardware
components (ie. projectors, cameras, lenses)


Making it Cost Effective: Post Processing

• Range of mesh editing tools to sample, filter, smooth, enhance, decimate,
align, merge, remesh, etc…point clouds and triangulated meshes.
li h i l d d i l d h
• Reverse Engineering modules allows users to create solid or surface models
from scan data.
• Inspection modules allows whole deviation 3D measurement for part
qualification.


Holding the Accuracy: Tracking the Positioner

The coordinate system of the positioner table needs to be accurate in order
for data alignment to be accurate.


Holding the Accuracy: Target Registration

• Align two scans together using features in your scan (ie. spheres).
• Recognizes th spheres and captures th center point of th sphere and
R i the h d t the t i t f the h d
use it for alignment.


Holding the Accuracy: Global Registration

ICP (Iterative Closest P i )
(I i Cl Point):
• Associate points by nearest neighbor criteria.
• Estimate transformation parameters using a
mean square cost function.
• Transform the points using the estimated
parameters.
• Iterate (re-associate the points and so on).
• Provides better accuracy.


Holding the Accuracy: Automation

• Use a positioner table with reference spheres for one button scanning.
• Then align the data using target registration with global alignment.


Case Studies: Accuracy

Single Camera Scanning and Alignment
g g g Simulation Scan - Ideal

46 sec 31 sec


Case Studies: Accuracy

Accuracy
Single Camera Scanning and Alignment Indicator

scan 1 vs scan 2 scan 2 vs scan 3 scan 3 vs scan 4

Simulation Scan - Ideal


Causes for Accuracy Distortion

Using a single camera:
Slight rotation creates mis-alignment of
projector and camera coordinate systems.


Solution: Accuracy Improved Using Two Cameras

Improve scan accuracy by using
two industrial cameras.


Case Studies:
Accuracy Improved Using Two Cameras
Accuracy
Two Camera Scanning and Alignment Indicator

scan 1 vs scan 2 scan 2 vs scan 3 scan 3 vs scan 4

Simulation Scan - Ideal

Case study proves that off-the-shelf hardware can produce accurate
results for quality inspection and aerospace at lower cost.


Reporting

Most post-processing software have
reporting function for quality inspection.


Automatic Reporting

Acquire Scan

Fixture Part Index Part End of Program Target Align Merge Report

Automate these steps


Automation Process

10 min

83 hours
h 8.16 hours
8 16 h
8 hour


Future Plans

• Experiment with different optical techniques/reconstruction algorithms to
E i t ith diff t ti l t h i / t ti l ith t
solve shiny part scanning without coating

• Multi scanner setup for faster quality inspection

• Large area scanning at high accuracies

• Deform mesh alignment – account for movement.

• High accuracy single camera calibration


Thank you!

Nasir Mannan Thomas Tong
CCAT 3D3 Solutions
nmannan@ccat.us thomastong@3d3solutions.com


Automated Low Cost 3D Scanning

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